Whats up with shims? IRS mark 4

[lcarpen]

for a mark iv...
i am finding that there are many shims with the rear irs suspension. however, it looks like the shims, especially around the shocks dont seem to fill the space. does anyone have a pic or two of the upper, lower and shock mounting point installed?

http://i374.photobucket.com/albums/oo182/lcarpen_2000/Mobile%20Uploads/20150510_092144_zps7b2mu1mz_edit_1431272684945_zps hszsl1ld.jpg
http://i374.photobucket.com/albums/oo182/lcarpen_2000/Mobile%20Uploads/20150510_092017_zpsji9xffy2_edit_1431272635681_zps t45vocfs.jpg
http://i374.photobucket.com/albums/oo182/lcarpen_2000/Mobile%20Uploads/20150510_092144_zps7b2mu1mz_edit_1431272684945_zps hszsl1ld.jpg

I have a bag of thin washers that I think go with the lower control arm but I would have to use about 16 shims on each. Is this correct?

[2bking]

The shims are intended for the lower control arms. For the space at the shock mounting you have two choices, tighten the bolt to torque spec and allow the tabs to bend or shim/make new spacers. I torqued the bolt to close the space. On a side note the lower shock mount spacers in the kit are wrong. If you use them, they decenter the shock and the top hat will bind at the lower extreme of movement. If I remember correctly, you will need two 5/8" spacers to center the shock.

You should have a build manual and it describes how to use the shims on the lower control arm. I had plenty of shims left over when I installed mine.

[lcarpen]

I dont think you should have to distort the brackets for fit. I checked where the shock mounts and control arm mounts are welded to the frame. The tabs are off as much as 3/4 in side to side.
The spacing between the tabs is off as much as 1/2 inch. I understand tolerances, maybe 1/8 inch, but this seems excessive.

[thardin]

Understanding that in the real world, manufacturing a "build it yourself kit" will have some inconsistencies in production, I took it upon myself to buy some proper Stainless Pipe with the proper ID and OD and just made my own shims for all of the shock mounts. Use a high grade stainless, measure the ears and preferred location for the shock, then cut custom shims for each location. relieve & chamfer the edges, polish them up, then scribe a location on each one. Helps during re-assembly when you take apart for repairs or maintenance. McMaster Carr or Online metals is a good source for the material and you will get away with one foot of material (cheap).

I agree, I would NOT deflect the tabs from their welded position as this could create a stress failure. Take the springs off the shocks and cycle the suspension to ensure you are not binding anywhere, then put the springs back on...

[CraigS]

For those of us who don't have a lathe to make custom length spacers, use a short spacer against the shock and stick a couple of washers at the control arm end of the spacer to make it tight.

[oldguy668]

I dont think you should have to distort the brackets for fit. I checked where the shock mounts and control arm mounts are welded to the frame. The tabs are off as much as 3/4 in side to side.
The spacing between the tabs is off as much as 1/2 inch. I understand tolerances, maybe 1/8 inch, but this seems excessive.

Sounds like a little bit of exaggeration. I've never (in 6 builds) found the tabs spacing to be off more than the thickness of a washer. The MK4 frame I'm working on now, which is 4 years old, used all the FFR spacers without issue.

[lcarpen]

i guess i may not be being clear. when i say side to side, i mean drivers side to passenger side. Not within the bracket itself. the pics show the gaps i an seeing within the bracket. i suppose i could take some pictures. i am glad noone else is seeing this as an issue though